STANDARD OPERATION PROCEDURE

Cage Forming

1. OperatorA. Ensure that the machine can run properly

i. Caging Machine (P400 and P600)(1) Check:

(a) Control panel(i) Ensure that all button can functional (ii) If there is problem immediately inform the Production Supervisor

Make sure all button can be functional

(b) Copper bar(i) Ensure that free from steel waste

Use grinder to grind away the steel waste(ii) Change the position (iii) Keep properly and do not lost it

If exhausted, use the other copper bar

Change the position

(c) Copper ring(i) Ensure that free from steel waste(ii) Change the position

Copper ring must free from steel waste

Rotate the copper ring

(d) Carbon brush(i) Check the condition, if there is abnormal immediately inform the Production

Supervisor

Carbon brush Check for abnormality

(e) Caging stand support(i) Ensure that all stand support can be functional(ii) Inform the Production Supervisor if there is problem immediately

(f) Plate guider

This hole always at 6 o’clock position

B. Set the machine to perform the specified cage size

C. Loaded the PC bars to the machine and secure in position

i. Check the lengthii. If PC bars uneven length segregate the PC bars

iii. Collect the shorter or longer PC bars until enough to produce a cage

How to check for uneven length

Can proceed

Segregate the bars

D. Use correct size of PC bars and spiral wire

i. Follow the table below:

Pile size (mm) No. PC bars x PC bars Dia. Spiral Dia. (mm)

250 6 x 7.1 mm 3.8

300 7 x 7.1 mm 3.8

350 9 x 7.1 mm 3.8

400 8 x 9.0 mm 3.8

450 8 x 9.0 mm 3.8

500 10 x 9.0 mm 4.0

600 14 x 9.0 mm 4.5

E. Initiate the machine by selecting the representative cage size

i. Select proper setting(1) Size (mm) – 250, 300, 350, 400, 450, 500, or 600(2) A, B or C for forming type based on size(3) Length (m) – 6, 9, 12, or 15 (4) Adjust the control for welding

(a) Heat control(b) Heat time

F. Inspect and verify the welding quality and pitch length as per specificationi. All loose welding shall be tied with G.I wires where applicable

(1) Tied at minimum 4 points

Loose cage shall be tied with G.I wire

4 points

Rearrange the spiral wire and tied at minimum 4 points

ii. Check pitch length

Tool for measure pitch length

How to use the tool

iii. Check the uneven length of PC bars cage

How to check:1. 2.

Can send the cage to the next section (assembly). Loose the uneven length of bars, rearrange the bars and tied back the bar with G.I wire. Do not easily

to destroy the cage. G. Record all the number and sizes of cage formed in auto cage forming records

i. Record based on actual hourly cage outputii. Reject cage must be recorded

2. SupervisorA. Ensure that the operators wear proper personal safety equipment.B. Monitor the cage forming process.C. Check the welding quality and pitch length as per specification.D. Ensure that the reject of cage must be clear at the end of the shift.E. Ensure that the PC bars from reject cage and recycle spiral wire need to be used.

PERFORMANCE REQUIRED

Size Length Qty. in 1 hour

250 6 289 1812 14

300 6 239 1512 12

350 6 209 1312 10

400 6 189 1112 9

450 6 169 1012 8

500 6 149 912 7

600 6 129 812 6